Cyclic electric welder and the like



July 19, 1949.

G. J. LEXA CYCLIC ELECTRIC WELDER AND THE LIKE Filed April 19, 1947 Patented July 19, 1949 CYCLIC ELECTRIC WELDER AND THE LIKE George J. Lexa, Wauwatosa, Wis.,

Cutler-Hammer,

poration of Delaware Application April 19, 1947, Serial No. 742,639

6 Claims. 1

The invention relates to a cycle controller and while not limited thereto is particularly applicable to electric resistance welding systems.

In resistance welding systems the parts which are to be welded together are connected into an electric circuit by means of a pair of electrodes which complete the circuit by pressing the parts together. Thereafter the circuit is energized, the current passing between the parts heating their points of contact and causing them to weld. In order to make a satisfactory weld it is necessary that the contact pressure between the parts be accurately regulated, that the total energy supplied to heat the contact be accurately measured and that after current interruption the parts be held under pressure for a sufficient time to allow the molten metal to solidify, whereupon the pressure may be released and the system readied for another weld by separation of the welding electrodes.

In some cases it is sufficient to supply a single welding impulse to an area on the workpiece which is to be welded, while in other cases it is desirable to supply in succession a number of Welding impulses to the same area. In either case it is necessary to accurately control the aforementioned steps of each cycle.

An object of the present invention is to provide a welding controller which permits accurate independent adjustment of the various intervals of a welding cycle.

Another object is to provide a timing circuit which is independent of the past history of an electron tube forming an element of the circuit.

Another object is to provide a timing circuit which compensates automatically for variations of the supply voltage.

Another object is to provide a timing circuit which is suitable for either high vacuum or gaseous tubes.

Another object is to provide a timing circuit whose control voltage comprises a constant amplitude D. C. component and a variable amplitude A. C. component, resulting in great accuracy of timing.

Another object is to provide a controller which delays the supply of welding energy for a sufficient time to assure that the pressure exerted on the work by the welding jaws has reached the required value.

Other objects and advantages will hereinafter appear.

The accompanying drawing shows a system embodying the invention. In the drawing,

assignor to Inc Milwaukee, Wis., a cor- Fig. 1 is a connection diagram of the yarious parts, while Fig. 2 shows in a well known manner the relationship of the energizing coils and the corresponding contacts of electromagnetic relays and other devices employed in the system illustrated by Fig. 1.

Referring to the drawing, a hydraulic welding machine is represented by a cylinder l0 having a piston I l to which is attached one electrode l2 connected to one terminal of a secondary winding I3 of a welding transformer I3 having a primary winding I3 The second terminal of the winding I3 is connected to a stationary anvil or electrode [4 of the welding machine. The parts to be welded together are introduced between the jaws l2 and I4 so that when the jaws are pressed together and the transformer 13 is energized, welding current passes between the jaws and through the parts to be welded to heat the parts to welding temperature.

The cylinder l 0 is supplied with actuating pressure fluid from any convenient source through a normally closed valve l5 having an electromag netic operating winding [5 which when energized opens the valve l5 to admit pressure fluid to the cylinder Ill. The pressure cylinder is also provided with a pressure responsive diaphragm l6, which as indicated in Fig. 2 is an operating medium for a switch IS. The winding l5 is supplied with energy from alternating current bus bars L L in a manner which will be described hereinafter.

Connected between the lines L L and in series with transformer winding [3 in inverse parallel with each other are the ignitrons l1 and I8. The ignition electrode I8 of ignitron I8 is connected through two half wave rectifiers 2|] and 20 to the anode of ignitron I! and the ignition electrode I! of ignitron I1 is similarly connected through two half Wave rectifiers I9 and l9 to the anode of ignitron [8. There is also connected across lines L L a primary winding 2| of a transformer 2|, which has a secondary winding 2| provided with an intermediate current tap. One end terminal of the Winding Zl is connected to a :bus bar 22. The intermediate tap is connected through a resistor 23 to a bus bar 25, while the other end terminal of the winding 2P is connected through normally disengaged contacts '50 to a bus bar 24. The intermediate tap of the winding 2| is also connected directly to a bus bar 25. Connected to the bus bar 22 are the cathodes of gaseous tubes 26, 21, 28 and 29, respectively.

Connected in parallel with each other across the bus bars 22 and 25 are potentiometer resistors 36, 35, 32 and 33. The movable contacts of these potentiometers are connected through capacitors 34, 35, 36 and 31, respectively, to the control electrodes of the tubes 26, 21, 23 and 29. Interposed between the respective capacitors and the corresponding control electrodes are the current limiting resistors'38, 39, 46 and 4|, respectively, while the capacitors are paralleled by discharge resistors 42, 43, 44 and 45, respectively. The anodes of the tubes 26, 21, 28 and 29 are connected respectively to electromagnetic windings 46 41 48 and 49 which windings as indicated in Fig. 2 are for electromagnetic switches 46, 41, 4B and 49, respectively. Each of the windings 46 41, 4B and 49 is preferably paralleled by a smoothing capacitor. The other terminal .of

the winding 43 is connected through the con-' tacts [6 to the bus bar 24, while the other terminals of the windings 41 48 and 49 are directly connected to the bus bar 24. The common point of the resistors 38 and 42 is connected through normally engaged contacts 50 and half wave rectifier 5| to bus bar 25, said rectifier permittingcurrent flow only towards the bus bar 25. Contacts 59 as indicated by Fig. 2 are contacts of' an electromagnetic relay 50. The common point of the resistors 43 and 39 is connected through normally engaged contacts 46 of electromagnetic relay 46 to and through a rectifier 52 to the bus bar 25. The common point of the resistors and 44 is connected through normally engaged contacts 41 of electromagnetic relay 41, toand through a rectifier 53, to the bus bar 25 and'the common point'of the resistors 4i and is connected through normally engaged contacts 48 of electromagnetic relay 46, to and through a'rectifier'54 to the bus bar 25. The rectifiers 52, 53 and 54 are half wave rectifiers which like rectifiers! permit current flow only toward bus are Connected in par'allel between the lines L L 'tl'iroughnormaHy disengaged contacts 55 and normally engaged contact 49 are electromagnetic windings and 5 5 which as indicated in Figv 2 are windings of electromagnetic relays 50 and respectively. A double throw single pole switch 56 when thrown inone direction connects a normally open push ,button switch 5! in parallel withthe series connected contacts 55 and IQ whilesaid switch 56 when thrown in the other direction "connects push button switch 51. in parallel withthe contact 55 only. The electromagnetic switch 48 is provided with normally engaged contacts 48 which are connected in series with normally disengaged contacts 55 of relay 55 and withwinding l5 across bus bars L L Connected between the-cathodes of the tubes [1 and l8 in series relation are normally disengaged contacts :46 of relay '46 and normally engaged cont acts 41 of relay'41 and a manual switch 58. The operation of the system thus far described .is'as follows:- If it is desired to make a weld :with a single current impulse the switch 58 is closed and "switch, 56 is moved to the position ;shown in the drawing. 'As the transformer 2| is energized the bus bars 22 and 25 are also ener- 'gized, and as the; contacts 56, 46, 41 and 48 are'closed, the condensers 34 to 31, inclusive, are charged to a high potential which causes the controlelectrodes of the tubes 26 to 29, inclusive, ,tobe'negative with respect to their cathodes, thus blocking current conduction by the respective cylinder I0. to bring the electrodes i2 and 14 together and 4 tubes during the positive half cycles of the voltage impressed upon said tubes.

The operator now closes momentarily the push button switch 51 thereby energizing relay coils 56 and 55 Energization of relay 53 engages contacts 555 thereby establishing a maintaining circuit for the coils 56 and 55, which passes through the normally engaged contacts 43 and parallels the push button switch 51 and switch '56. Energization of relay 55 also engages contacts 55 thereby completing the energizing circuit for the winding l5", which causes opening of the valve I5 to admit pressure fluid to the The piston I l is moved downwardly to exert pressure on the material pressed therebetween which closes the circuit for the welding coil E3 As the pressure in the cylinder rises the pressure switch I6 closes the contacts lB This completes connections for the winding 46, but said winding is not energized due to the negative potential on the control electrode of tube 26. However, the contacts 53 are disengaged at the moment of energization of the relay 53 so that now the charging circuit for the capacitor 3c is interrupted and the latter discharges through the resistor 42 until finally the negative voltage impressed upon the control electrode of the tube 26 is sufficiently reduced to permit conduction of said tube.

It should be noted here that the voltage which is impressed upon the control electrode of tube 26 consists of the unidirectional voltage impressed thereupon by the capacitor on which is superposed an alternating potential derived from the potentiometer resistor 36. As a result the rate of change of the control electrode voltage at the moment it passes through the critical voltage value at whichthe tube becomes conducting is relatively high even though the rate of change of the capacitor voltage is low, thus affording a very precise control of the moment during the half cycle when the tube 26 becomes conducting. The same observation also holds true for the operation of the tubes 21 to 29, inclusive.

It will be further noted that in case the contacts 50 should be engaged and the contacts 50 disengaged prior to engagement of contacts .16 the tube 26 is prevented from conducting due to the interruption of its'circuit by the contacts [6 This assures that the timing by the tube 26 does not start until sufficient pressure is developed between the electrodes l2 and I4. As soon as relay 46 is energized it engages the normally disengaged contacts 46* and disengages the normally engaged contacts 46. Engagement 0f contacts 46 completes a circuit from line L through half wave rectifier 28 contact 46 and normally closed contact 47 switch 58, half wave rectifier w to the ignition electrode Il through the cathode of tube l1 and through the transformer winding l3", to line L and alternately from line L through transformer Winding l3 half wave rectifier I9 ,switch'58, contacts 4? and 46 half wave rectifier 23 to electrode 18 of tube l8 so that the tubes I! and l8'beoome alternately conducting during their respective half cycles to energize the transformer l3 for supply of welding current to the welding electrodes l2 and I4, through the transformer winding 13 Opening of the contact 46 disconnects the ca pacitor 35 from the bus bar 25 and permits the same to discharge until the negative potential of the tube 21 becomes sufficiently low to permit conduction ofthe tube 21. This energizes the winding of relay 41 which thereupon opens the normally closed contact 41 and the normally closed contact 41. Opening of contact 41* interrupts the circuit which supplies energy to the ignition electrodes H and IV, so that the conduction of the tubes [1 and I8 and supply of welding current to the welding jaws l2 and I4 is interrupted. Opening of the contact 41 permits conduction of the tube 28 after a time delay determined by the discharge of the capacitor 36 in the manner aforedescribed, whereupon the tube 28 becomes conducting thus energizing the relay coil 48 which opens the normally closed contacts 4 and 48. Opening of contact 48 interrupts supply of pressure fluid to the cylinder It so that pressure between the jaws l2 and I 4 upon the weld is released. Opening of contact 48 affords discharge of the capacitor 31 and after a certain time has elapsed the tube 29 becomes conducting thereby energizing relay 49, which causes opening of the contact 49 to deenergize relay windings 50 and 55 and returns the systerm to the condition prevailing at the start of the cycle just described. Should the push button switch 51 be held depressed during and after the entire cycle described, the relays 50 and 55 would not be deenergized upon operation of relay 49. In that event contact 50 would remain closed at the end of the cycle, maintaining energization of relays 4B, 41, 48 and 49, so that there would not be any pressure on the welding jaws l2 and M due to continued disengagement of contacts 48*.

If it should be desired to test the cycle of the equipment without supplying welding current it is only necessary to open the switch 58 thereby interrupting the supply of energy to the ignition electrodes l1 and I8 but in all other respects the system functions as aforedescribed.

Should it be desired to repeat the welding cycle periodically as long as the push button switch 51 is depressed, the switch 56 is moved to its lowermost position, Upon initial closure of the push button switch the circuit operates as aforedescribed, except that opening of the normally open maintaining contact 55 of relay 55 is now inoperative to terminate operation at the end of an individual cycle so that the cycle is repeated until the push button 51 is released.

What I claim as new and desire to secure by Letters Patent is:

l. The combination with a plurality of electroresponsive windings to be energized progressively subiect to predetermined timing and an altercurrent supply source, of like but separate and independently adjustable timing circuits for said windings, each comprising a grid type electron tube, a resistor and capacitor in parallel and a rectifier, and each also comprising connections between a grid of said tube and said source to render the tube conducting in response to alternate half cycles of voltage of said source and connections to supply its capacitor from said source through its rectifier to superimpose a unidirectional voltage on the alternating voltage impressed upon its grid, thereby to block conduction by the tube, and means to control the latter connections of the several circuits for unblocking their tubes progressively in the desired order of response of said windings, the capacitor of each circuit when relieved of the impressed unidirectional potential gradually discharging to permit its respective tube to be rendered conducting.

2; The combination with a plurality of electroresponsive windings to be energized progressively subject to predetermined timing and an alternating current supply source, of like but separate and independently adjustable timing circuits for said windings, each comprising a grid type electron tube having its main path connected in series with the respective winding, a resistor and capacitor in parallel and a rectifier, and each also comprising connections between a grid of said tube and said source to render the tube conducting in response to alternate half cycles of voltage of said source and connections to supply its capacitor from said source through its rectifier to superimpose a unidirectional voltage on the alternating voltage impressed upon its grid, thereby to block conduction by the tube, each. capacitor when relieved of such unidirectional voltage gradually discharging to permit its respective tube to become conducting, and means to control said timing circuits to so relieve their capacitors progressively in the desired order of response of said windings, the last mentioned means comprising switches individualized to different timing circuits and operable by certain of said windings respectively.

3. The combination with a plurality of electro responsive windings to be energized progressively subject to predetermined timing and an alternating current supply source, of like but separate and independently adjustable timing circuits for said windings, each comprising a grid type electron tube having its main path connected in series circuit with the respective winding, means to connect said several series circuits in parallel with each other to said source, a resistor and capacitor in parallel and a rectifier, andeach also comprising connections between a grid of said tube and said source to render the tube conducting in response to alternate half cycles of voltage of said source and connections to supply its capacitor from said source through its rectifier to superimpose a unidirectional voltage on the alternating voltage impressed upon its grid, thereby to block conduction by the tube, and switches, each responsive to energization of one of said windings and each controlling one of said timing circuits to relieve its respective capacitor of the unidirectional voltage to which it is subject, each such capacitor when relieved of the impressed unidirectional voltage gradually discharging to permit its respective tube to become conducting.

4. The combination with a plurality of electroresponsive windings to be energized progressively subject to predetermined timing and an alternating current supply source, of like but separate and independently adjustable timing circuits for said windings, each comprising a grid type electron tube, having its main path connected in series circuit with the respective winding, means to connect said several series circuits in parallel with each other to said source, a resistor and capacitor in parallel and a rectifier, and each also comprising connections between a grid of said tube and said source to render the tube conducting in response to alternate half cycles of voltage of said source and connections to supply its capacitor from said source through its rectifier to superimpose a unidirectional voltage on the alternating voltage impressed upon its grid, thereby to block conduction by the tube and switches individualized to said timing circuits for progressively relieving the capacitors of the latter of the unidirectional superposed voltage to permit the respective tubes to become conducting progres- 7 sively subject to gradual discharge of the respective capacitors, one of said switches requiring operation by means other than said windings but the remainder of said switches being operable by said windings respectively.

5. The combination with a plurality of electroresponsive windings to be energized progressively subject to predetermined timing and an alternating current supply source of like but separate and independently adjustable timing circuits for said windings, each comprising a grid type electron tube having its main path connected in series with the respective winding, a resistor and capacitor in parallel and a rectifier and each also comprising a potentiometer connected to said source and connections between a grid of said tube and an adjustable tap of said potentiometer tending to render the tube conducting for an adjustable portion of alternate half cycles of voltage of said source and connections to supply its capacitor from said source through its rectifier and its potentiometer to superimpose a unidirectional voltage on the alternating voltage impressed upon its grid, thereby to block conduction by the tube, and means to control said timing circuits for unblocking their tubes progressively in the desired order of response of said windings, each such capacitor when relieved of the impressed unidirectional potential gradually discharging to permit its respective tube to be rendered conducting as aforestated.

6. The combination with a plurality of electroresponsive windings to be energized progressively subject to predetermined timing and an alternating current supply source, of like but separate and independently adjustable timing circuits for said windings, each comprising a grid type electron tube, having its main path connected in series circuit with the respective winding, means to connect said several series circuits in parallel with each other to said source, a resistor and capacitor in parallel and a rectifier, and each also comprising connections between a grid of said tube and said source to render the tube conducting in response to alternate half cycles of voltage of said source and connections to supply its capacitor from said source through its rectifier to superimpose a unidirectional voltage on the alternating voltage impressed upon its grid, thereby to block conduction by the tube, switches, each responsive to energization of one of said windings and each controlling one of said timing circuits for unblocking the respective tube, thus to effect unblocking of said tubes progressively in the desired order of response of said windings, each such capacitor when relieved of the impressed unidirectional potential gradually discharging to permit its respective tube to be rendered conducting as aforestated, and means to render automatic or non-automatic selectively repetition of a given cycle of response of said windings.

GEORGE J. LEXA.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date Re. 19,896 Alexanderson Mar. 24, 1936 1,939,462 Ramsay Dec. 12, 933 1,988,274 Glaser Jan. 15, 1935 2,337,905 Livingston Dec. 28, 1943 

